Mounting system for solar panels, bearing member for same and associated methods

ABSTRACT

The present invention relates to a mounting system ( 1 ) for mounting one or more solar panels (P). The mounting system ( 1 ) comprises: a plurality of elongate bearing members ( 10 ) adapted to be arranged spaced apart and substantially parallel to one another on a rooftop surface, and in particular on an outer sealing membrane (S) of the rooftop, and a plurality of fastening straps ( 20, 20 ′) for fastening the bearing members ( 10 ) to the rooftop surface. Each of the bearing members ( 10 ) is adapted for mounting a solar panel (P) or a support frame (F) of a solar panel thereon, and each of the fastening straps ( 20 ) is adapted to engage one or more of the bearing members ( 10 ) and includes a securing region ( 21 ) for securing the strap to the rooftop surface. In this regard, each of the fastening straps ( 20, 20 ′) is arranged, in use, to extend from one of the bearing members ( 10 ), preferably such that the securing region ( 21 ) of each fastening strap ( 20, 20 ′) is outside or beyond a vertical projection of the respective bearing member ( 10 ) on the rooftop surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119(a)-(d) ofEuropean Patent Application No. 09009922.7, which was filed with theEuropean Patent Office on Jul. 31, 2009, and should therefore beafforded the right of priority of this earlier filing date. Thedisclosure of this European Patent Application No. 09009922.7 isincorporated herein in its entirety.

TECHNICAL FIELD

The present invention relates to a mounting system for mounting one ormore solar panels, and to an elongate bearing member for such a mountingsystem. A method of mounting a solar panel and a method of forming abearing member according to the invention are also described.

The mounting system of the invention and the associated bearing memberare particularly suitable for use in mounting solar panels on flatrooftops covered with a sealing layer, such as a polymeric, bituminous,or tar-based membrane, and it will be convenient to describe theinvention in this exemplary context. It will be appreciated, however,that the mounting system and the bearing member of the invention arealso suitable for use on other types of rooftops or supportingstructures.

BACKGROUND

As a result of an increasing trend towards the adoption of renewableenergy sources, the installation of solar panels, and in particular ofarrays of photo-voltaic panels, is gaining in popularity, not only forindustrial and institutional applications, but also in the domestic andrural environments. Whether for the industrial, institutional, domesticor rural environment, the solar panels are often mounted on the rooftopsof buildings—most typically in the area where the solar energy isrequired. Roof structures are particularly convenient for this purposeas they present a large surface area directed towards the sun and areoften largely out of view from the normal visual perspective, therebyrendering the installations relatively unobtrusive. Horizontal or flatrooftops are particularly convenient for this purpose as they provide aneven and stable working environment for the assembly, installation andmaintenance of a solar panel array.

In many cases, horizontal or flat rooftops have a sealing layer as anouter covering and this sealing layer is typically formed by a flexiblemembrane of a rubber-based or polymer material, sometimes includingbituminous or tar-based compounds. In particular, the sealing layer or“skin” of flat rooftops is often formed by one or more sheets of aflexible material selected from the group including thermoplasticpoly-olefins (TPOs) or flexible polyolefins, flexible polyolefin alloys(FPA), ethylene-propylene-diene M-class rubber (EPDM),poly-vinylchloride (PVC) and polymer-bitumen sheeting. Some of thesematerials have been in use in roofing structures since the 1960s and, assuch, are commonly found on the rooftops of existing buildings today.

Such rooftops present particular problems in the mounting of solar panelarrays because it is especially important to ensure that the outersealing layer or membrane of the rooftop remains intact and that no, oronly minimal, perforation or penetration of the sealing layer occurs. Inthis regard, the flexible outer layer or membrane serves to ensure aseal against the ingress of water into the roof structure. Accordingly,every time the outer sealing layer or membrane sustains a perforation orpuncture, the waterproof properties of the membrane are compromised anda potential source of rainwater leakage or seepage into the roof iscreated.

One of the known techniques for mounting of solar panel arrays on suchflat rooftop surfaces includes the use of elongate bearing rails as thebasic carrier elements for the solar panel array. The bearing railstypically have a constant profile or cross-section (sometimes called a“cap”- or “hat”-section) and have conventionally been fastened orsecured on the sealed outer surface of the rooftop in a number ofdifferent ways, including being held down with weights or ballast, boltsand screw fasteners, adhesive and solvent bonding, and cold or hotfusion or welding. These techniques have disadvantages, however.

The use of weights or ballast is cumbersome and is not appropriate forall rooftops because it substantially increases the loading on the roofstructure. Bolts and screw fasteners have the disadvantage that theycause a penetration of the roof “skin” or sealing layer, which—as notedabove—carries the inherent risk of a possible subsequent seepage orleakage of water into the roof structure. This risk is furtherheightened in the event that the solar panel array ever needs to bedisassembled and removed from the rooftop.

Adhesive bonding and solvent bonding have the disadvantage of relativelylow bond durability and can also not be employed for all types ofconventional sealing layer or sealing sheet material. On the other hand,the technique discussed in German utility model DE 20 2008 209 134 U1,which describes the use of cold fusion or welding to secure the bearingrails to the roof surface, requires that the bearing rails first becoated with a material that corresponds to the sealing layer (e.g. PVC,TPO, EPDM, etc.), which can be extremely time- and cost-intensive.Furthermore, hot fusion or welding using a heating device with thatarrangement can be difficult due to the rigidity of the rails and canlead to irregular bonding and associated failures.

All of the above fixation techniques also have the further disadvantagethat forces generated due to thermal expansion of the solar panelmodules arranged on and/or extending between the rail sections, have tobe fully absorbed by the join between the rail and the sealing layer onthe rooftop. With significantly different coefficients of thermalexpansion between the roof structure and the solar modules, overloadingor even tearing of the sealing layer can result.

In view of the above problems associated with conventional mountingsystems for solar panel arrays on rooftops sealed with a polymer orrubber-based sheet layer or membrane, it is an object of the presentinvention to provide a new and improved mounting system with which oneor more of these problems may be overcome or at least minimized. It isalso an object of the invention to provide an improved bearing rail foruse in such a mounting system, and a method of forming such a bearingrail.

SUMMARY

According to one aspect, the present invention provides a mountingsystem for one or more solar panels, comprising: a plurality of elongatebearing members adapted to be arranged spaced apart and substantiallyparallel to one another on a rooftop surface, and a plurality offlexible securing members for securing the bearing members to therooftop surface. Each of the bearing members is adapted for supportingand mounting a solar panel or a fixation frame of the solar panelthereon. Each of the securing members is adapted to extend from at leastone of the bearing members and includes a securing region adapted to befastened to the rooftop surface.

In a preferred form of the invention, each of the flexible securingmembers is configured or arranged to extend from the respective bearingmembers such that the securing region of that securing member isarranged outside a plan or vertical projection of the bearing memberonto the rooftop surface. In other words, the securing region ispreferably arranged for fastening to the rooftop next to or adjacent therespective one of bearing members. For example, the securing region ofeach flexible securing member may be arranged to be fastened to therooftop surface at one or more lateral side or longitudinal end regionof the bearing member. The securing region of each flexible securingmember is desirably to be fastened to the outer rooftop surface byadhesive bonding or by fusion or welding, such as hot or cold welding.Preferably, each of the flexible securing members is configured orarranged in use to extend over, across, and/or through at least one ofthe bearing members.

In a preferred form of the invention, each of the flexible securingmembers is formed substantially entirely from a flexible web ofmaterial, which may be compatible for adhesive or fusion bonding withthe rooftop surface, such as, for example, any one of TPO, FPA, EPDM,PVC and/or a bituminous polymer. Alternatively, however, each of theflexible securing members may be only partially flexible. That is, eachof the flexible securing members may comprise both a flexible portion(as above) and a substantially rigid portion. In a particular embodimentof the invention, each of the flexible securing members may be formed asa fastening strap.

According to another aspect, the present invention provides a mountingsystem for mounting one or more solar panels, comprising: a plurality ofelongate bearing members adapted to be arranged spaced apart andsubstantially parallel to one another on a rooftop surface, and aplurality of fastening straps for fastening the bearing members to therooftop surface. Each of the bearing members is adapted for mounting asolar panel or a support frame of a solar panel thereon, and each of thefastening straps is adapted to engage at least one of the bearingmembers and includes a securing region for securing the strap to therooftop surface. By engaging one or more of the bearing members, eachfastening strap acts to hold the respective bearing member securely inposition on the rooftop.

In a preferred form of the invention, each of the fastening straps isconfigured or arranged, in use, to extend from one of the bearingmembers, e.g. in such a manner that the securing region of eachfastening strap is arranged outside a vertical projection of therespective bearing member on the rooftop surface. In this way, thesecuring region of each fastening strap may be arranged to be fastenedto the rooftop surface at one or more lateral side and/or one or morelongitudinal end region of the bearing member. The securing region ofeach fastening strap is desirably adapted to be secured to the rooftopsurface by adhesive bonding or by fusion or welding (e.g. hot or coldwelding). In use, each fastening strap is preferably arranged to extendover, across, and/or through a respective one of the bearing members. Assuch, the portion of the strap which extends over, across, and/orthrough the bearing member engages that bearing member to hold or“strap” it securely to the roof.

In a preferred form of the invention, each fastening strap is at leastpartially, and preferably substantially entirely, formed as a flexibleweb, and preferably comprises a material compatible for adhesive orfusion bonding with the rooftop surface. In this way, each fasteningstrap may be formed such that at least the securing region of the strapis suitable for adhesive or welded fastening to the rooftop surface. Forexample, the strap is desirably formed as a web of any one of TPO, FPA,EPDM, PVC and/or a bituminous polymer. In this connection, the materialof the fastening straps may be selected depending upon the material ofthe outer sealing layer or membrane on the rooftop and/or the type ofbonding or welding to be used. The fastening strap may comprise aflexible web of any suitable size and shape for performing the desiredfunction; i.e. it may be relatively long and narrow, or it may even begenerally square or sheet-like. The decisive aspect in this respect isthat the dimensions enable the fastening strap to perform the intendedfastening function with the bearing member. The securing region of eachfastening strap is desirably provided at an end region of the strap andpresents an area for adhesion or fusion bonding with the rooftopsurface. It will be noted, however, that the present invention alsocontemplates embodiments in which each of the fastening straps may beformed from a substantially rigid material. In such embodiments, thefastening straps may nevertheless still be suitable to be secured to therooftop surface by adhesive bonding or by fusion or welding (e.g. hot orcold welding).

In a preferred form of the invention, each bearing member comprises atleast one opening or recess for receiving one of the fastening strapswhen the fastening strap is arranged to extend over, across, and/orthrough the bearing member. In a particular preferred form of theinvention, the at least one opening or recess includes one or moreaperture formed in each of the bearing members for receiving one of thefastening straps with the strap extending transversely across and/orthrough the bearing member. In this regard, the one or more aperture maybe formed as a slot through which the strap extends.

In a preferred form of the invention, each bearing member comprises: abase having at least one footing for supporting the bearing member onthe rooftop surface, and an attachment region for attaching a solarpanel or a support frame for the solar panel to the bearing member.Preferably, the attachment region is at an upper part of each bearingmember and is spaced from the footing by one or more wall extendingupwardly from the footing. Furthermore, in a particularly preferred formof the invention, each bearing member is formed as a channel section,more preferably as a U-shaped channel section, and most preferably as a“hat”- or “cap”-section.

In light of this preferred structure of the bearing member, the one ormore aperture (e.g. slot) in the bearing member through which arespective one of the fastening straps is desirably arranged to extendis preferably located between the footing and the attachment region ofthe bearing member, and preferably adjacent or in close proximity to thefooting such that, in use, the respective fastening strap extendstransversely across the bearing member over the footing.

In another particularly preferred form of the invention, the at leastone opening or recess for receiving one of the fastening straps includesa cavity or channel formed in an end region of each bearing member toreceive the fastening strap in an axial direction. In this connection,the cavity or channel may be formed in the at least one footing of thebearing member and may have an opening at the end region of the bearingmember for insertion of the fastening strap.

In a preferred form of the invention, one or more of the plurality offastening straps is/are adapted to engage the respective bearing membervia a physical connection to the bearing member, and preferably to afooting of the bearing member, e.g. by one or more connector elements orfasteners, such as rivets, or by adhesive connection.

The mounting system of the present invention provides numerousadvantages when compared with conventional solar panel mounting systemsdescribed at the outset. For example, the mounting system of theinvention avoids the need for any puncture or penetration of an outersealing layer or membrane covering the rooftop with bolt- or screw-typefasteners. In addition, the mounting system of the invention enablessubsequent removal of the solar panel array and the bearing memberswithout any damage to an outer sealing layer or membrane on the rooftop.That is, the straps may be cut or severed to leave just the bondedsecuring region thereof attached to the rooftop, while the rest of thesolar panel array and mounting system and can be disassembled andremoved from the rooftop. The outer sealing layer that covers therooftop thus remains entirely intact and unaffected.

According to another aspect, the present invention provides a solarpanel assembly comprising a solar panel mounting system according to theinvention as described above, and one or more solar panels to be mountedon the mounting system.

According to a further aspect, the present invention provides a bearingmember for mounting a solar panel or a support frame for a solar panelon a rooftop surface, the bearing member having:

a base comprising at least one footing for supporting the bearing memberon the rooftop surface;

an attachment region for attaching the solar panel or the support framefor the solar panel to the bearing member; and

means for receiving and/or engaging a fastening strap which isconfigured or designed to extend from the bearing rail.

In a preferred form of the invention, the means for receiving and/orengaging the fastening strap comprises at least one opening or recessfrom which and/or through which the fastening strap extends in use. Theat least one opening or recess is preferably provided between the baseand the attachment region of the bearing member. The at least oneopening or recess may, for example, include an aperture for receivingthe fastening strap extending transversely across or through the bearingmember, with the aperture preferably being configured as a slot.

In a preferred form of the invention, the attachment region is at anupper part of each bearing member and is spaced from the footing by oneor more side walls extending upwardly from the footing. Thus, the atleast one aperture is preferably provided through the one or more sidewall adjacent or in close proximity to the footing such that therespective fastening strap extends transversely over the footing.

In a further preferred form of the invention, the at least one openingor recess from which and/or through which the fastening strap extends inuse as a means for receiving and/or engaging the fastening strapcomprises a cavity or channel formed in an end region of the bearingmember from which the fastening strap extends in an axial direction. Inthis connection, the cavity or channel may be formed in the at least onefooting of the bearing member and may have an opening at the end regionof the bearing member for insertion of the fastening strap.

According to still a further aspect, the present invention provides amethod of mounting one or more solar panels or a support frame of asolar panel on a rooftop surface, the method comprising the steps of:

arranging a plurality of elongate bearing members spaced apart andsubstantially parallel to one another on a rooftop surface, wherein eachof the bearing members is adapted for mounting a solar panel or asupport frame of a solar panel thereon; and

providing a plurality of fastening straps for securing the bearingmembers to the rooftop surface, wherein each of the fastening straps hasa securing region to be fastened to the rooftop surface, and

arranging each of the fastening straps to engage at least one of thebearing members, preferably such that a securing region thereof extendsfrom the respective one of the bearing members.

According to yet another aspect, the present invention provides a methodof forming a bearing member for mounting a solar panel or a supportframe for a solar panel on a rooftop surface, the method comprising thesteps of:

providing an elongate strip of sheet material;

forming one or more apertures in the elongate strip of sheet material,whereby if more than one, the apertures are spaced apart from oneanother in a longitudinal direction;

folding a central portion of the elongate strip of sheet material toform an attachment region of the bearing member for attaching the solarpanel or the support frame for the solar panel thereto; and

folding a lateral or peripheral portion of the elongate strip of sheetmaterial to form a base having at least one footing for supporting thebearing member on the rooftop surface.

In a preferred form of the invention, the apertures are formed in aregion of the elongate strip between the attachment region formedfolding a central portion of the elongate strip and the footing formedby folding a lateral or peripheral portion of the elongate strip. Thestep of forming the one or more apertures preferably includes cutting,punching or stamping a plurality of apertures longitudinally spacedapart from one another along the strip of sheet material. The aperturesmay, for example, be formed as elongate slots.

In a preferred form of the invention, the step of folding a centralportion of the elongate strip of sheet material includes folding thestrip along two substantially parallel fold-lines that extendlongitudinally centrally of the strip. The elongate strip is preferablyfolded through at least approximately 90° along each of these twosubstantially parallel central fold-lines, whereby each fold is in anopposite direction about a longitudinal axis of the strip, such that thefolded portions are preferably folded towards one another.

In a preferred form of the invention, the step of folding a lateral orperipheral portion of the elongate strip includes folding the stripalong substantially parallel fold-lines extending longitudinally of thestrip along opposite lateral or peripheral edge regions of the elongatestrip. The strip is preferably folded through at least about 90° alongeach of these fold-lines at the opposite lateral or peripheral edgeregions of the strip, whereby each fold is in an opposite directionabout a longitudinal axis of the strip. The direction of each of thesefolds about the longitudinal axis is preferably opposite to the folddirection of an adjacent central portion fold-line.

In a particularly preferred form of the invention, the step of foldingthe lateral or peripheral portion of the elongate strip further includesfolding opposite outermost lateral or peripheral edge regions of theelongate strip through about 180°, with each of these folds being in anopposite direction about a longitudinal axis of the strip. In this way,a slot-like cavity or channel may be formed in the footing for receivinga fastening strap in an axial direction, as discussed above. This andother aspects of the invention will become more clear from the followingdescription with reference to the drawings.

It will be appreciated that the terms “upper”, “lower”, “upwardly”,“downwardly”, “lateral”, “laterally” as well as other similar terms usedherein in respect of various parts of the mounting system and bearingmember of the invention are intended to be given their ordinary meaningin view of the normal or in-use orientation of the mounting systemdescribed herein. It will also be appreciated, however, that otherinterpretations of these terms may be appropriate depending on theparticular orientation of the system and/or its respective parts at thetime.

The details of one or more variations of the subject matter describedherein are set forth in the accompanying drawings and the descriptionbelow. Other features and advantages of the subject matter describedherein will be apparent from the description and drawings, and from theclaims.

BRIEF DESCRIPTION OF DRAWINGS

The above and further features and advantages of the invention willbecome more readily apparent from the following detailed description ofpreferred embodiments of the invention with reference to theaccompanying drawings, in which like reference characters identify likefeatures, and in which:

FIG. 1 is a perspective view of a mounting system for mounting a solarpanel on a rooftop according to a conventional arrangement;

FIG. 2 is a cross-sectional view of a bearing member for a solar panelmounting system according to a preferred embodiment of the presentinvention;

FIG. 3 is a longitudinal side view of the bearing member shown in FIG.2;

FIG. 4 is a cross-sectional view of a mounting system (or part thereof)for mounting a solar panel according to a preferred embodiment of thepresent invention;

FIG. 5 is a plan or top view of the mounting system of the inventionshown in FIG. 4;

FIG. 6 is a plan or top view of a mounting system (or part thereof)according to an embodiment of the invention showing an end region of abearing member;

FIG. 7 is a cross-sectional view along the lines A-A through themounting system shown in FIG. 6;

FIG. 8 is a detailed view of that part of the mounting system in FIG. 7labelled “C”;

FIG. 9 is a cross-sectional view along the lines B-B through themounting system shown in FIG. 6;

FIG. 10 is a side view of a mounting system (or part thereof) formounting a solar panel according to an embodiment of the invention;

FIG. 11 is a plan or top view of the part of the mounting system shownin FIG. 10;

FIG. 12 is a top or plan view of a blank for forming a bearing memberaccording to a preferred form of the invention, the blank shown in asmall format with dimensions given in millimetres;

FIG. 13 is a cross-sectional view of a bearing member according to anembodiment of the invention and largely corresponding to FIG. 2, butshown in a small format with dimensions given in millimetres and showingthe fold-lines 111, 121 and 122 of the blank;

FIG. 14 is a detailed view of that part of the blank in FIG. 12 labelled“Y”; and

FIG. 15 is a detailed view of that part of the blank in FIG. 14 labelled“Z”.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Firstly, FIG. 1 of the drawings shows a schematic arrangement of some ofthe parts of a mounting system 1 of the invention with which a solarpanel P is mounted on a sealed surface of a flat rooftop R. For the sakeof simplicity, the mounting system 1 in FIG. 1 only shows a single pairof elongate bearing members 10 arranged spaced apart and substantiallyparallel to one another on the outer sealing layer S of the rooftop R,and a single solar panel P is shown supported by the system 1. It willbe appreciated, however, that the solar panel mounting system 1 willtypically comprise many more of the elongate bearing members 10, andwill be configured to support a large number of solar panels P. Someelements of a frame F for supporting and/or fixing the solar panel P canbe seen attached to an upper or top part of the bearing members 10. Thisframe F may be designed to orient or position the solar panel P at aparticular pitch or angle relative to the surface of the rooftop foroptimal collection of the sun's rays. In this embodiment, therefore, thesolar panel(s) P is/are not directly attached to the elongate bearingmembers 10, but rather is/are fixed to the frame F which is supportedand attached on the bearing members. The solar panel P, which may be anyone of the various different photovoltaic modules currently available,is arranged extending between the two substantially parallel bearingmembers 10.

As will be appreciated by the skilled reader, the bearing members 10 aretypically straight elements with a substantially uniform or constantcross-section and may, for example, be formed from aluminium, althoughother materials, such as other metals (e.g. steel) or polymer plastics(e.g. polyethylene HDPE or polyurethane PU) are also contemplated by thepresent invention. The bearing members 10 essentially form elongatestructural elements upon which the solar panels are (either directly orindirectly) mounted and supported in the framework of the mountingsystem 1. The bearing members 10 will hereafter also be referred to asbearing sections or bearing “rails”, as they are often known in the art.

With reference now to FIGS. 2 and 3 of the drawings, a bearing rail 10according to one preferred embodiment of the invention will bedescribed. The bearing rail 10 has an essentially uniform cross-sectionalong its length and is formed as a channel section or “cap”-section, assuch profiles are sometimes called. In this connection, the bearing rail10 comprises a base region 11 consisting of two laterally oppositefootings 12, each being in the form of a laterally outwardly projectingflange which extends along substantially the entire length of thebearing rail 10. It will be noted that each of the flange-type footings12 in this embodiment of the bearing rail 10 comprises a pair of upperand lower plate members 13 created by forming the flange from plate orsheet material which is folded or doubled-over on itself through about180°. The outermost lateral edge 14 of each of the footings 12 maythereby be provided with a curved or rounded profile, which preventsdamage to the outer sealing layer or membrane S when positioning thebearing member 10 on the rooftop R. The upper and lower plate members 13in each of the footings 12 of this embodiment of the rail 10 create orform a narrow, slot-like channel or cavity 15 there-between. This aspectof the footings 12 will be discussed in more detail later.

As is particularly apparent from FIG. 2, the bearing rail 10 comprisesan inverted, substantially right-angled U-shaped section having asubstantially horizontal upper part 16 which forms an attachment regionfor attaching a solar panel P either directly thereto or for attachingelements of the support frame F upon which the solar panel P is thenmounted. Attachment of a solar panel P or a support frame F to thehorizontal attachment region 16 of the bearing rail 10 is typicallyperformed using screw or bolt fasteners. Furthermore, in this embodimentof the bearing rail 10, generally vertical side walls 17 of the railextend from the footings 12 to the attachment region 16 at the upperpart thereof.

With particular reference to FIG. 3, it will be noticed that the bearingrail 10 in this embodiment also includes three apertures 18 in the formof elongated rectangular slots arranged at regular intervals spacedapart along the length of the bearing rail. These apertures 18 areformed in alignment through the opposite side walls 17 of the railsection at positions located adjacent or in a close proximity to thefootings 12 which extend at the laterally opposite sides of the bearingrail 10.

The purpose of this particular configuration of the bearing rail 10becomes clearer with reference to FIGS. 4 and 5 of the drawings, whichillustrate the components of the mounting system 1 of the invention inuse on a sealing layer S of a rooftop. The slot-like apertures 18 formedthrough the side walls 17 of the bearing rail 10 are designed to receiveand accommodate flexible strap members 20. The straps 20 are formed asflexible webs, strips, or sheet members, and each is designed to beinserted through a respective one of the rectangular slots 18 such thatthe straps 20 extend transversely across the bearing rail 10 with anopposite end region 21 of each strap extending from the rail and beingrespectively located at a lateral side thereof.

In this particular embodiment of the invention, the end regions 21 ofeach of the straps 20 forms a securing region for fixedly securing thestrap to the sealing layer S forming the outer surface or waterproof“skin” of the rooftop R. In this regard, at least the end securingregions 21 of each fastening strap 20 are formed from a material that issuitable for adhesive or solvent bonding or fusion/welding with thematerial of the outer sealing layer S of the rooftop. For example, theend securing regions 21 (and optionally the entirety) of each fasteningstrap 20 may be formed from a material selected from the groupconsisting of thermoplastic polyolefins (TPOs), flexible polyolefinalloys (FPA), ethylene-propylene-diene M-class rubber (EPDM),polyvinylchloride (PVC) and polymer-bitumen. Each of the straps 20, onthe other hand, also includes an engagement region—in this embodiment,in a central region thereof—which engages the respective bearing rail10, e.g. via the slots 18 and via contact with the upper side of thefootings 12, to hold the rail in position on the roof.

Thus, as can be seen in FIG. 4, the securing regions 21 are securelybonded to the sealing layer S of the rooftop such that each of thefastening straps 20 forms a restraining member for holding the bearingrails firmly in position on the surface of the rooftop. The securingregions 21 can be seen to be arranged and bonded to the outer sealinglayer or membrane S in an area outside a plan or vertical projection ofthe respective bearing rail 10 on the rooftop surface—that is, areaswhich are laterally to either side of the footings 12 of the bearingmember. Nevertheless, the fastening straps 20 reliably operate toprevent any unwanted lateral movement of the bearing rails 10, which arethus effectively bound or strapped to the rooftop surface. A small spaceor gap G may be left between each of the footings 12 and the adjacentbonded securing region 21 of each strap 20 to allow for thermalexpansion of the bearing rails 10. The straps 20 themselves, however,may be sufficiently resilient to accommodate an amount of expansionshould little or no gap G be provided.

In this connection, during installation of a bearing rail 10 in themounting system 1 of this embodiment, one end region 21 of a fasteningstrap 20 may firstly be bonded or welded to the sealing layer S of therooftop surface on one side of the bearing rail, and subsequently theopposite end region 21 of the same strap 20 may be tensioned against thecompleted bond or weld before bonding or welding is carried out at thesecond end region. That is, each of the straps 20 can be tensioned inengagement over the bearing rail 10 (i.e. in this case, over thefootings 12 of the rail) to ensure a stable and secure strapping of thebearing member to the rooftop surface. If the straps 20 are fastened tothe sealing layer S by welding, conventional heating or welding devicesfor fusing flexible webs or membranes in roofing applications may beused. Because an end region of each fastening strap 20 extends from therails 10 and the securing regions 21 are thus located beyond or outsidea vertical projection of the rails, the welding or fusing procedure canbe carried out in an uncomplicated manner.

By dimensioning each of the fastening straps 20 to have a width w thatsubstantially corresponds to the length of each of the slots orapertures 18 formed through the side walls 17 of the bearing rail 10,each of these straps 20 may also acts to prevent any unwantedlongitudinal displacement of the bearing rail. That is, under theinfluence of forces (e.g. from wind gusts, thermal expansion) which mayact upon the bearing rails 10 in a longitudinal direction, side edgeregions 22 of each of the fastening straps 20 may bear against the ends23 of each of the slots or apertures 18 to restrict longitudinalmovement of the rail. Of course, if the bearing rails 10 are made ofaluminium or another metal, such as steel, it can be desirable to formthe edges 23 of the slots 18 with a rounded profile and/or to providethe side edge regions 22 of each of the fastening straps 20 with adurable or robust structure to prevent and/or minimize any potentialcutting or tearing the material of the straps 20 as a result of contactwith ends 23 of the slots. As an alternative, the width w of the straps20 may be dimensioned so as to be slightly smaller than the length ofthe slots 18, such that the edge regions 22 do not ordinarily come intocontact with the slot ends 23. As the ordinary skilled person willappreciate, the actual shape and/or dimensions of the fastening straps20 can be selected as desired. For example, in the embodiment shownschematically in FIG. 5 of the drawings, each of the straps 20 consistsof a generally rectangular sheet, and each one of these sheet-likestraps 20 is inserted through a pair of the slot-like apertures 18formed aligned in the side walls 17 of the cap section to extendtransversely across the bearing rail 10. It will be noted, however, thatthe straps 20 could also be formed as relatively thin strips and thattwo or more fastening straps could, at least potentially, be insertedthrough each of the apertures 18—though such an arrangement could makefor a more complicated or more cumbersome installation of the mountingsystem 1 of the invention. In FIG. 5 of the drawings, it will also benoticed that curved or rounded corners c are shown in broken lines as anoptional feature of the footings 12 in the base 11 of the bearing rail10. Such rounded corners c are designed to minimise the risk ofinadvertently tearing or puncturing the outer sealing layer S of theroof while the rails 10 are being positioned on the rooftop duringassembly and installation of the solar panel array.

Referring now to FIGS. 6 to 9 of the drawings, an alternative and/oradditional technique for achieving longitudinal fixation and/orstability of the bearing rails 10 in the mounting system 1 of theinvention is illustrated. According to this aspect of the invention, thenarrow channel or cavity 15 formed between the upper and lower platemembers 13 of each of the footings 12 has an opening 24 at an end regionof each bearing rail 10, and this narrow channel or cavity 15 is able toreceive an end fastening strap 20′ in an axial direction. In particular,as can be clearly seen with reference to FIG. 6 and FIG. 9, the endfastening strap 20′ of a substantially flexible material can be insertedinto the narrow slot-like cavity or channel 15 defined by each of thefootings 12 such that a portion (approximately half) of the end strap20′ is arranged within the footings (shown in broken lines in FIG. 6)and approximately half of the strap 20′ extends from an axial end 25 ofthe bearing rail. That part of the fastening strap 20′ within theslot-like cavity 15 between the upper and lower plate members 13 can bephysically connected to the bearing rail 10 via one or more connectingelements 19, such as rivets, as illustrated in FIGS. 7 and 8 of thedrawings. The end region 21 of the strap 20′ which projects or extendsfrom the axial end 25 of the bearing rail 10 then forms a securingregion for adhesive bonding or hot/cold welding to the sealing layer S,as discussed before.

The individual bearing rails according to the present invention arepreferably fabricated in lengths of 3000 mm or 6000 mm, though otherlengths can be selected as desired. When the rooftop R upon which thesolar panel array is to be provided has an extensive surface area, it isnot unusual that two or more bearing rails 10 are arranged axiallyaligned with each other, in addition to a parallel arrangement of thebearing rails. In this connection, FIGS. 10 and 11 of the drawingsillustrate an embodiment of the mounting system 1 in which two bearingrails 10 are arranged in axial alignment with one another. In thisembodiment, a small gap 26 (e.g. 15 mm) has been left between theopposite ends 25 of the two bearing rails 10. This gap 26 permits somerelative movement in an axial direction between the two rails 10 of themounting system 1, which may arise e.g. due to thermal expansion. Themounting system 1 includes a joining member 27, such as a joining plate,which is adapted to be rigidly fixed by screws 28 to the top orattachment region 16 at the end 25 of one of the two bearing rails,while a slot 29 and the respective pin/screw 28 connection allowrelative displacement of the end 25 of the other bearing rail. It willbe noted that, where a plurality of rails 10 are arranged and connectedin axial alignment with each other as shown in FIGS. 10 and 11, no useis typically made of axially extending end straps 20′ (as per FIGS. 6 to9) at the connected end regions 25 of the bearing rails 10. Rather, endfastening straps 20′ which extend axially from the cavity or channel 15for longitudinal stabilisation of the rails 10 are typically onlyemployed at the extreme opposite ends 25 of the composite (i.e.combined) bearing rails 10.

With reference now to FIG. 12 of the drawings, a top or plan view of ablank 100 for forming a bearing rail 10 according to a preferred form ofthe invention is shown in a small format with dimensions given inmillimetres. Similarly, FIG. 13 of the drawings shows a cross-sectionalview of a bearing member according to an embodiment of the invention ina small format with dimensions given in millimetres. It will beappreciated that the dimensions shown are for illustrative purposesonly, and that the dimensions of the blank 100 (and thus of the rail 10)can be modified and selected to meet the demands of the specific solarpanel array to be installed.

FIGS. 14 and 15 of the drawings illustrate the fold-lines fortransforming a blank 100 fabricated from e.g. a sheet of aluminium intoa bearing rail 10 according to the invention. In this connection, themethod of forming a bearing rail 10 for mounting a solar panel Pcomprises the steps of providing the blank 100 e.g. in the form of anelongate strip of aluminium sheet material, and cutting, punching, orstamping a plurality of the slot-like apertures 18 longitudinally spacedapart from one another along the strip of sheet material. A centralportion 110 of the elongate blank 100 is provided with two substantiallyparallel fold-lines 111 which extend longitudinally centrally of theblank 100. The blank 100 is folded through approximately 90° along eachof these substantially parallel central fold-lines 111, whereby thesefolds are in opposite directions about a longitudinal axis X of thestrip, such that the folded portions are folded towards one another toform the upper attachment region 16 in the centre of the bearing rail 10and the depending side walls 17.

Furthermore, two laterally opposite or peripheral portions 120 of theblank 100 are provided with substantially parallel fold-lines 121 thatextend longitudinally of the blank along opposite lateral or peripheraledge regions thereof. The blank 100 is folded through about 90° alongeach of these fold-lines 121 at the laterally opposite or peripheralportions 120, whereby these folds occur in opposite directions about thelongitudinal axis X of the strip to form a base 11 comprising twofootings 12 for supporting the bearing rail 10 on the rooftop surface.The laterally opposite or peripheral portions 120 each have a furtherlongitudinally extending fold-line 122, each of which is folded throughabout 180°, with these folds again being in opposite directions aboutthe longitudinal axis X of the blank 100 to complete the formation ofthe two footings 12 with upper and lower plate members 13, and with thefold-line 122 corresponding to the rounded edge 14.

It will be appreciated that the above description of the preferredembodiments of the invention with reference to the drawings has beenmade by way of example only. Accordingly, a person skilled in the artwill appreciate that various changes, modifications and/or additions maybe made to the parts particularly described and illustrated withoutdeparting from the scope of the invention as defined in the appendedclaims.

1-16. (canceled)
 17. A mounting system for mounting one or more solarpanels, comprising: a plurality of elongate bearing members adapted tobe arranged spaced apart and substantially parallel to one another on arooftop surface, wherein each of the bearing members is adapted formounting a solar panel or a support frame for a solar panel thereon; anda plurality of fastening straps for fastening the bearing members to therooftop surface, wherein each of the fastening straps is adapted toengage at least one of the bearing members and includes a securingregion for securing the strap to the rooftop surface; wherein each ofthe elongate bearing members comprises a channel section of sheetmaterial, and wherein the fastening straps are arranged to extendtransverse to a longitudinal extent of the bearing members.
 18. Amounting system according to claim 17, wherein each of the fasteningstraps is arranged to extend from the bearing members such that thesecuring region of each fastening strap is arranged beyond a verticalprojection of the respective bearing member on the rooftop surface. 19.A mounting system according to claim 17, wherein the securing region ofeach fastening strap is adapted to be secured to the rooftop surface byadhesive bonding, by solvent bonding, or by cold or hot fusion orwelding.
 20. A mounting system according to claim 17, wherein each ofthe elongate bearing members comprises: a base having at least onefooting for supporting the bearing member on the rooftop surface, and anattachment region above the footing for attaching the solar panel or thesupport frame to the bearing member, the attachment region being spacedfrom the footing by one or more wall member extending upwardly from thefooting.
 21. A mounting system according to claim 20, wherein eachfooting comprises a laterally outwardly projecting flange that extendslongitudinally of the bearing member, the flange having upper and lowerplate members defining a slot-like channel or cavity there-between. 22.A mounting system according to claim 20, wherein each bearing member hasa pair of opposite laterally outwardly projecting footings.
 23. Amounting system according to claim 20, wherein at least one opening orrecess is provided through the said one or more wall member forreceiving a respective one of the fastening straps such that thefastening strap extends transversely over the footing.
 24. A mountingsystem according to claim 17, wherein each bearing member furthercomprises an opening or recess formed in an end region thereof forreceiving one of the fastening straps in an axial direction.
 25. Amounting system according to claim 24, wherein the opening or recessformed in the end region of the bearing member is in the form of aslot-like cavity or channel.
 26. A mounting system according to claim24, wherein each of the fastening straps received in the axial directionis attached to the respective bearing member by one or more fasteners orby adhesive.
 27. A mounting system according to claim 17, wherein eachfastening strap is at least partially formed from a flexible material,and wherein the securing region is provided at an end region of thestrap and presents an area for adhesive bonding, for solvent bonding, orfor cold or hot fusion or welding with the rooftop surface.
 28. Amounting system for mounting one or more solar panels, comprising: aplurality of elongate bearing members adapted to be arranged spacedapart and extending substantially parallel to one another on a rooftopsurface, wherein each of the bearing members is adapted for mounting asolar panel or a support frame for a solar panel thereon; and aplurality of fastening straps for fastening the bearing members to therooftop surface, wherein each of the fastening straps is adapted toengage at least one of the bearing members and includes a securingregion for securing the strap to the rooftop surface; wherein each ofthe elongate bearing members has a longitudinally extending channel andat least one footing that projects laterally outwardly from the channelfor supporting the bearing member on the rooftop surface; and whereineach bearing member is configured to receive at least one of thefastening straps in an axial direction at an end region thereof.
 29. Amounting system according to claim 28, wherein each of the fasteningstraps received in the end region of the respective bearing member isattached to the bearing member by one or more fasteners.
 30. A mountingsystem according to claim 28, wherein each of the elongate bearingmembers comprises at least one cavity or channel formed in the endregion thereof for receiving the fastening strap in an axial direction.31. A mounting system according to claim 28, wherein each elongatebearing member further comprises an attachment region above the footingfor attaching the solar panel or support frame to the bearing member.32. A mounting system according to claim 28, wherein some of theplurality of fastening straps are arranged to extend transverse to alongitudinal extent of the bearing members.
 33. In a solar panelmounting system, an elongate bearing rail for mounting a solar panel ora support frame of a solar panel on a rooftop surface, the bearing railbeing formed from sheet material and comprising: a base having a pair ofopposed, laterally outwardly projecting footings for supporting thebearing rail on the rooftop surface; an attachment region at an upperpart of the bearing rail above the footings for attaching the solarpanel or the support frame of the solar panel to the bearing rail; and apair of opposite wall members extending upwardly from the base andinterconnecting the attachment region with the footings; wherein thebearing rail comprises at least one opening or recess from which and/orthrough which a fastening strap is adapted to extend in use.
 34. Abearing rail according to claim 33, wherein the at least one opening orrecess comprises one or more apertures formed through each of the pairof opposite wall members for receiving a respective fastening strapwhich extends from or transversely across or through the bearing rail.35. A bearing rail according to claim 34, wherein each aperture isprovided in close proximity to the footing such that the respectivefastening strap is configured to extend transversely over the footing.36. A bearing rail according to claim 34, wherein each aperture is aslot.
 37. A bearing rail according to claim 33, wherein the at least oneopening or recess from which and/or through which the fastening strap isadapted to extend in use is formed in an end region of the bearing railfor receiving one of the fastening straps in an axial direction.
 38. Abearing rail according to claim 37, wherein the at least one opening orrecess formed in the end region of the bearing rail is a slot-likechannel or cavity.